Protection Circuit Test, Test Description | Lincoln Electric V250-S

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F-35	TROUBLESHOOTING & REPAIR	F-35
	TROUBLESHOOTING & REPAIR

PROTECTION CIRCUIT TEST

WARNING

Service and repair should be performed only by Lincoln Electric factory trained per- sonnel. Unauthorized repairs performed on this equipment could result in danger to the technician or the machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precau- tions detailed throughout this manual.

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric service department for technical troubleshooting assistance before you proceed.

Call (216) 383-2531 or (800) 833-9353 (WELD).

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TEST DESCRIPTION

This check will aid the technician in the understanding and evaluation of the V250-S protec- tion circuit.

MATERIALS NEEDED

Voltmeter/ohmmeter (Multimeter)

Machine wiring diagram

Protection circuit simplified wiring diagram

INVERTEC V250-S

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Lincoln Electric V250-S service manual Protection Circuit Test, Test Description

Contents

Invertec V250-S Safety ARC Rays can burn Electric Shock can killFumes and Gases can be dangerous Welding Sparks can cause fire or explosion Cylinder may explode if damaged Sûreté Pour Soudage a L’Arc Précautions DE Sûreté Master Table of Contents for ALL Sections Table of Contents Installation Section Installation Three Phase Single Phase Technical Specifications Invertec V250-SThree Phase Input Connections Safety PrecautionsSelect Suitable Location Input Fuse and Supply Wire Input Voltage Reconnect ProcedurePower Input Connection for 50/60 HZ Machines Output Cables Remote Control ReceptacleOutput Connections Quick Disconnect Plugs Invertec V250-S Operation Gouging Sparks Safety Instructions Figure B.1 Case Front Controls Controls and Settings TIG Welding Constant Current ProcessesManual ARC Welding Stick AIR Carbon ARC Cutting Overload Protection Parallel OperationThermal Protection Invertec V250-S Table of Contents Accessories Section Accessories Remote Controls Options / AccessoriesCable Plugs Table of Contents Maintenance Section Maintenance Figure D.1 Location of Input Filter Capacitor Terminals Input Filter Capacitor Discharge Procedure Filter Capacitor Conditioning Routine Maintenance Figure D.2 Location of Maintenance Components Theory of Operation Table of Contents Theory of Operation Section Input Line Voltage General Description Figure E.2 Protection and PRE-CHARGE Circuits Precharge and Protection Figure E.3 Main Transformer Main Transformer Figure E.4 Output Rectification and Control Output Rectification Control Overload Protection Protection Circuits Insulated Gate Bipolar Transistor Igbt Operation Minimum Output Pulse Width ModulationMaximum Output Troubleshooting & Repair Oscilloscope Warning HOW to USE Troubleshooting Guide Board can be dam- aged by static electricity PC Board Troubleshooting Procedures Course of Action Possible Areas Recommended Symptoms Perform the Control Board Voltage Checks Possible Areas Capacitor Balance Test Troubleshooting & Repair Perform the Output Diode Test Welding Problems Invertec V250-S Test Description Auxiliary Transformer TestMaterials Needed Auxiliary Transformer Test Test Procedure Table F.1 Auxiliary Transformer Test Points Auxiliary Transformer Test Invertec V250-S Input Rectifier Test Input Rectifier Test Test Procedure Test Point Terminals Analog Meter X10 Range Table F.2 Input Rectifier Test Points Invertec V250-S Power Board Resistance Test Test Description Power Board Resistance Test Table F.3 Power Board Resistance Test Points Power Board Resistance Test Invertec V250-S Output Diodes Test Figure F.4 Machine Output Terminals Output Diodes Test Invertec V250-S Diode Modules Power Board Voltage Test Figure F.8 Plug J6 on Power Board Power Board Voltage Test Acceptable Test Description Table F.4. Power Board Voltage Test PointsTest Conditions Invertec V250-S Control Board Voltage Test Figure F.9 Plugs J1-J5 on Control Board Control Board Voltage Test 18VAC Table F.5. Control Board Voltage Test Points Invertec V250-S Protection Circuit Test Figure F.10 Control Board Plug J2 Test Points Protection Circuit Test Protection Circuit Simplified Invertec V250-S Capacitor Balance Test Capacitor Balance Test Figure F.12 Power Board and Capacitor Test Locations Table F.6 Capacitor Voltages Invertec V250-S Control Board Removal and Replacement Procedure Control Board Removal and ReplacementV250S Control Power Board Removal and Replacement Figure F.14 Power Board Lead Locations Power Board Removal and Replacement Power Board Replacement Procedure Invertec V250-S Matched Parts Filter Capacitor Removal and Replacement Figure F.15 Heatsink/Power Board Removal Filter Capacitor Removal and Replacement Perform Power Board Replacement Procedure in this section Invertec V250-S Input Rectifier Bridge Removal and Replacement Figure F.16 Input Rectifier Lead Locations Input Rectifier Bridge Removal and Replacement Troubleshooting & Repair Invertec V250-S Materials Needed Snubber Resistors Locking Tabs Invertec V250-S Wrench Allen type wrench Torque wrench Mounting Bolts Diode Modules Bolted Connections Troubleshooting & Repair Invertec V250-S Main Transformer Removal and Replacement Machine Codes below T3 Current Transformer Main Transformer Main Transformer Secondary Leads Figure F.22 Main Transformer Mountings Clear all leads and secure for case wrap-around assembly Invertec V250-S Main Transformer Removal and Replacement Machine Codes Above Figure F.23 Main Transformer Right Side Figure F.24 Main Transformer Left Side Figure F.25 Main Transformer Mountings Troubleshooting & Repair Invertec V250-S Input Idle Amps and Idle Watts Maximum Acceptable Output AT Minimum Output SettingsMinimum Acceptable Output AT Maximum Output Settings Retest After Repair Invertec V250-S Electrical Diagrams Invertec V250-S Invertec V250S Wiring Diagram Codes 10102 Return to Section Wiring Diagram Codes 10187 G2666 Control PC Board G2666 Layout Power P.C. BD. Asbly Power PC Board G2684 Layout Relay Coils Control PC Board G2666 Schematic From Control BD Power PC Board G2684 Schematic